Refractory materials

Patent metadata

Field	Value
Publication number	US-2025145541-A1
Application number	US-202318504894-A
Country	US
Kind code	A1
Filing date	Nov 8, 2023
Priority date	Nov 8, 2023
Publication date	May 8, 2025
Grant date	—

Abstract

In some examples, a method for making a refractory component includes depositing carbon on a surface of a refractory substrate. The carbon fills surface voids on the surface of the refractory substrate. A melting point of the refractory substrate is greater than or equal to about 1500 degrees Celsius (° C.). The method includes applying a metal slurry to a surface of the refractory substrate following the deposition of the carbon and reacting a metal of the metal slurry with the carbon to form a metal carbide phase within the surface voids of the refractory substrate.

First claim

What is claimed is:

1 . A method for making a refractory component, the method comprising:
depositing carbon within surface voids of a refractory substrate, wherein a melting point of the refractory substrate is greater than or equal to about 1500 degrees Celsius (° C.); applying a metal slurry to the refractory substrate following the deposition of the carbon; and reacting a metal of the metal slurry with the carbon to form a metal carbide phase within the surface voids of the refractory substrate.

2 . The method of claim 1 ,
wherein the metal carbide phase and a surface portion of the refractory substrate define a surface layer, wherein a porosity of the surface portion of the refractory substrate is greater than about 10 percent by volume (vol. %), and wherein a porosity of the surface layer is less than about 5 vol. %.

3 . The method of claim 1 , wherein the refractory substrate comprises at least one of at least one of magnesia, alumina, silica, calcia, zirconia, or chamotte.

4 . The method of claim 1 ,
wherein the metal of the metal slurry comprises silicon, and wherein the metal carbide phase comprises silicon carbide.

5 . The method of claim 1 , wherein the refractory substrate comprises silicon nitride.

6 . The method of claim 1 , further comprising, prior to depositing the carbon, forming the refractory substrate.

7 . The method of claim 6 , wherein the refractory substrate comprises at least one of a reaction bonded silicon nitride, a reaction bonded silicon carbide, or a nitride bonded silicon carbide.

8 . The method of claim 6 , wherein forming the refractory substrate comprises:
pressure casting silicon powder into a mold having a predetermined shape corresponding to a shape of the refractory component; and reacting the silicon powder with nitrogen gas to form the refractory substrate comprising silicon nitride.

9 . The method of claim 8 , wherein reacting the silicon powder with the nitrogen gas includes heating the silicon nitride below a melting temperature of the silicon.

10 . The method of claim 8 , wherein a porosity of the pressure casted silicon powder is greater than about 20 vol. %.

11 . The method of claim 8 , wherein a porosity of the refractory substrate is greater than about 25 vol. %.

12 . The method of claim 1 ,
wherein a surface portion of the refractory substrate includes a carbon matrix, and wherein the method further comprises reacting the metal of the metal slurry with carbon of the carbon matrix to form a metal carbide coating on an outer surface of the refractory substrate.

13 . The method of claim 1 ,
wherein the refractory component is a component of a foundry system, wherein the refractory component defines an oxidation-resistant surface configured to contact molten metal, and wherein the refractory component comprises at least one of a ladle, a slide gate, a liner, or an interior portion of a vessel.

14 . An article of a foundry system, the article comprising:
a refractory component defining an oxidation-resistant surface configured to contact molten metal, wherein the refractory component comprises:
a refractory substrate, wherein a melting point of the refractory substrate is greater than or equal to about 1500 degrees Celsius (° C.); and
a metal carbide phase within surface voids of the refractory substrate.

15 . The article of claim 14 ,
wherein the metal carbide phase and a surface portion of the refractory substrate define a surface layer, wherein a porosity of the surface portion of the refractory substrate is greater than about 10 percent by volume (vol. %), and wherein a porosity of the surface layer is less than about 5 vol. %.

16 . The article of claim 14 , wherein the refractory substrate comprises at least one of magnesia, alumina, silica, calcia, ferric oxide, titania, silicates, zirconia, or chamotte.

17 . The article of claim 14 , wherein the metal carbide phase comprises silicon carbide.

18 . The article of claim 14 , wherein the refractory substrate comprises silicon nitride.

19 . The article of claim 14 ,
wherein the refractory substrate includes a carbon matrix, and wherein the refractory component further comprises a metal carbide coating on an outer surface of the refractory substrate.

20 . The article of claim 14 ,
wherein the high temperature article comprises a vessel, wherein the oxidation-resistant surface of the refractory component is configured to contact molten metal, and wherein the refractory component comprises at least one of a ladle, a slide gate, a liner, or an interior portion of a vessel.

Assignees

• Honeywell Int Inc

Inventors

• Mehr Mehrad
• Jadidian Bahram
• Blinn Kevin

Classifications

• C04B35/66 Primary

  Monolithic refractories or refractory mortars, including those whether or not containing clay {(making or repairing of linings F27D1/16)} · CPC title

• C04B2111/0087

  for metallurgical applications · CPC title

• C04B2111/00939

  for the fabrication of moulds or cores · CPC title

• C04B41/5001

  with carbon or carbonisable materials · CPC title

• C04B41/009

  characterised by the material treated · CPC title